A high power multifunctional test bench includes the following diagnostic functions: diagnostics of starters, alternators and voltage regulators without applying any additional measuring devices. The test bench was invented on the basis of the requirements of modern service stations: construction implies mounting of majority of units without using additional fixing elements. The bench tests units of 12V and 24V; diagnoses the latest alternators and voltage regulators, which are controlled by car ECU; has ports to connect alternators of different brands and manufacturers: «COM» («LIN», «BSS»), «P-D», «DFM», «D+», «RLO», «C», «SIG». Diagnostics is carried out through load simulation of car consumers, change of rotation speed, sending of control signals (external control alternators), tracking of electrical characteristic. Testing results are transmitted to LCD display real-time. Testing modes are switched with membrane keyboard on the control panel of the test bench. The selected mode is lightened with the corresponding indicator. The equipment carries out testing of different alternators under load up to 200A. Power supply is single-phase 380V.
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The equipment set includes:
|Supply voltage, V||380±10%|
|Voltage of tested alternators, V||12/24|
|Drive power, kW||5,5|
|Load on a tested alternator, A||12V - up to 200A, 24V - up to 100A|
|Drive speed, rpm||0-3000|
|Drive speed direction||Left/right|
|Drive speed adjustment||Smoothly|
|Transmission type (drive/alternator)||Belt|
|Dimensions, (L×W×H), mm||555×455×1060|
|Belt type||V belt; timing belt|
|Read parameters||Voltage; alternating current; direct current; drive rotation; DFM (alternator load control indicator, %)|
|Voltage of tested starters, V||12/24|
|Power of tested starters, kW||Up to 6|
|Measured parameters||Voltage; alternating current; direct current|
|Voltage of tested voltage regulators, V||12/24|
|Tested parameters of voltage regulators||Stabilizing voltage; rotor winding current; COM voltage regulators: protocol; speed of exchange; type of regulator; errors|
|Voltage measurement accuracy, V||0,1|
|Current measurement accuracy, A||0,1|
|Short circuit protection||Yes|
|Short circuit sound alert||Yes|
|Terminals of tested voltage regulators||"COM" (BSS, LIN), "P-D", "DFM", "D+", "RLO", "C", "SIG", "F/67"|
The method of checking the solenoid starter switch described below assumes the use of a test bench MS002COM for starters and alternators.
Having secured the starter on the bench, it is necessary to connect the power clamp to the housing of the unit, output "50" to the control actuator of the solenoid and press the "START" button. In the case of a working state, the armature will move smoothly in the solenoid starter switch relay. Otherwise, the relay needs repair or replacement.
The jamming of moving parts of the drive on the shaft of the starter armature arises from the contamination of the splined part of the shaft and the formation of an oxide coating on its surface. The movement check is performed either manually or by means of the test bench, feeding the supply voltage to the solenoid starter switch of the starter. When the power supply is disconnected, the pinion and the drive coupling (bendix) must return to their original position under the action of the spring.
It is also likely slippage of the freewheel clutch. To find this, attach a torque of 2-2.5 times the nominal torque to the gear in the direction opposite to its rotation. Malfunction of the coupling arises because of the wear of the rollers and grooves under them in the cage of the hub of the pinion, or because of the strong contamination of the inner space of the clutch, which causes one or more rolls to freeze in a suspended state. In this case, it is recommended to flush the clutch using gasoline or a liquid for cleaning brake calipers.
This situation is possible as a result of violation of the equipment operation rules, or as a result of power supply voltage pulsation.
The most common cause of this malfunction is the ignition of the contacts of the magnetic switch. The solution is to replace the starter with a new one.